Automotive vehicle HVAC rainhat

ABSTRACT

In a preferred embodiment, the present invention provides a high temperature injection molded polymeric rainhat for a heating, ventilation, and air-conditioning air intake of an automotive vehicle is provided. The rainhat includes a flange for adhesively and sealably joining to a portion of the generally planar automotive vehicle cowling encircling a flared air inlet opening. A water dam joined to the flange extends beyond an end of the flared opening. The water dam has an extreme upper edge forming an opening. A foreign matter ingestion preventer has a plurality of first curvilinear supports extending in a first direction over the water dam upper edge opening. Each first support has opposite ends joined with the water dam, and each first support has a middle portion domed above the opening of the water dam. Each first support has a tapered exterior side. The foreign matter ingestion preventer also has plurality of second supports intersecting with the first curvilinear supports. Each second support has a middle portion being domed above the water dam. Each second support has a tapered exterior side. A surface area of the foreign matter ingestion preventer minus the surface area defined by the transverse dimensions of the first and second supports is generally equal to or greater than the area defined by the opening of the upper edge of the water dam.

FIELD OF THE INVENTION

The field of the present invention is that of rainhats for heating,ventilation, and air-conditioning inlets on automotive vehicles.

BACKGROUND OF THE INVENTION

Virtually all vehicles manufactured today have a heating and ventilationsystem for the interior of the vehicle. Additionally, virtually allvehicles manufactured in North America also come equipped with anair-conditioning system. To facilitate the environmental health andcomfort of the vehicle occupants, fresh air must be brought into thevehicle interior. Several technical challenges are presented in bringingin fresh air into the vehicle. First, the fresh air intake should belocated in an area of the vehicle such that it cannot suck in any fumesfrom the engine compartment. Secondly, the fresh air intake should bepositioned in a location that snow or frozen precipitation cannot clogit up. Additionally, the air intake should be protected so thatprecipitation and/or leaves or other various debris and does not enterinto the heating, air-conditioning and ventilation system.

Most vehicles place the engine in the front end of the vehicle. Behindthe engine compartment is a sealed interior of the vehicle which isprovided by a fire wall. Above the fire wall and inclined rearwardlyfrom the top of the fire wall is the windshield. Extending forwardlyfrom the base of the windshield and on top of the fire wall is agenerally flat region called the cowling. The cowling is covered by therear portion of the front hood which also extends across the enginecompartment. The lower portion of the hood has a seal molding whichseals the engine compartment from the remainder of the cowling. However,the engine hood is spaced away from the windshield allowing air to enterinto the cowling area from behind the front hood. Typically, the airintake for most vehicles is placed in the cowling area since the cowlingarea is opened to the atmosphere, covered by the front hood but yetsealed away from the engine compartment by the molding of the fronthood. The cowling typically has a flared opening for the air inlet forthe heating, ventilation and air-conditioning system. Air from the airinlet is piped into the interior of the vehicle below the dashboardwhere it is appropriately heated, cooled and/or filtered to meet theenvironmental and comfort requirements of the vehicle occupants.Although the cowling is covered, it is exposed to the environment andrain falling down the windshield does enter the cowling area until it isdiverted to the sides away from the cowling. To prevent the water whichaccumulates in the cowling area from entering into the inlet for theheating, ventilation and air-conditioning system, a rainhat is provided.Prior to the present invention, the rainhat included a tubular-shapedmember having a bottom flat flange. The tubular shaped member wasinserted over a flared opening of the cowling and was spot weldedthereto. The area of contact of the rainhat flange with the cowling wassealed to prevent the inflow of water. After the tubular shaped memberwas weldably attached to the flared opening of the cowling, a screen hadto be attached over the tubular shaped member to prevent the ingestionof leaves or other debris into the heating and ventilation system. Thescreen was weldably attached to an encircling metallic band. Themetallic band was either fixed to the tubular shaped member by welding,fasteners or clips. The screen was joined along its sides to themetallic band and typically had a generally flat top end.

Prior rainhats suffered from several problems. The first problem was thecost. The prior rainhat had a tubular shaped member, a metal band, threeclips and a wire mesh screen. The screen (and encircling metallic band)could not be placed on the tubular shaped member until the tubularshaped member was assembled into the vehicle since the spot welding gunshad to be inserted within the tubular shaped member during thefabrication process. Additionally, it was not uncommon for the spotwelds to break. When the spot weld breaks, typically a portion of thetubular shaped member or of the flared opening is torn leaving a crackwhich gives a potential for the ingestion of rain water into theheating, ventilation and air-conditioning system air intake. To protectthe ends of the screen, the screen was usually inserted into theencircling metallic band. This allowed a potential gap between thescreen and the top end of the encircling metallic band to be created.The above noted gap could allow for the entry of leaves or other debriswhich could then become stuck and clog up the air intake opening bybeing sucked against the screen.

It is desirable to provide a rainhat which can be affixed with theflared opening of the cowling without the expense of a weldingoperation. It is also desirable to provide a rainhat which is cheaper tomanufacture. It is still another desire to provide a rainhat which islighter allowing the vehicle to have an increase in gas mileage andthereby increase the environmental efficiency of the vehicle.

To meet the above-noted desires, the revelation of the present inventionis brought forth. The present invention provides the freedom of a singleintegral rainhat which may be adhesively and sealably connected with anautomotive vehicle without the utilization of any welding. Furthermore,in a preferred embodiment, the present invention brings forth a hightemperature injection molded polymeric rainhat which can be fabricatedin a single drawn injection machine. Furthermore, the present inventionprovides a rainhat which is cheaper, easier to install and whichadditionally can be formed in a shape which discourages the entrapmentof leaves or other articles which can clog up the openings.

In a preferred embodiment, the present invention provides a hightemperature injection molded polymeric rainhat for a heating,ventilation, and air-conditioning air intake of an automotive vehiclehaving a cowling with a generally planar surface encircling a flaredopening. The rainhat includes a flange for adhesively and sealablyjoining to a portion of the generally planar cowling encircling theflared opening.

A water dam is integrally joined to the flange and is extendingtherefrom. The water dam has an interior surface closely engaging theflared opening of the cowling and extends upwards beyond a vertical endof the flared opening. The water dam has an extreme upper edge formingan opening. A foreign matter ingestion preventer is also included. Theforeign matter ingestion preventer has a plurality of first curvilinearsupports extending in a first direction over the water dam upper edgeopening. Each first support has opposite ends joined with the water dam,and each first support has a middle portion domed above the opening ofthe water dam. Each first support has a tapered exterior side. Theforeign matter ingestion preventer also has plurality of second supportsintersecting with the first curvilinear supports. Each second supporthas a middle portion being domed above the water dam. Each secondsupport has a tapered exterior side. A surface area of the foreignmatter ingestion preventer minus the surface area defined by thetransverse dimensions of the first and second supports is generallyequal to or greater than the area defined by the opening of the upperedge of the water dam.

It is an object of the present invention to provide an injection moldedrainhat for the air intake of an automotive heating, ventilation andair-conditioning system.

The above-noted objects and other advantages of the present inventionwill become more apparent to those skilled in the art as the inventionis further explained in the accompanying detailed description anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of a high temperature injectionmolded polymeric rainhat for a heating, ventilation, and air intake foran automotive vehicle according to the present invention which includesa flange, a water dam, and a foreign matter ingestion preventer.

FIG. 2 is a side elevational view of the rainhat shown in FIG. 1.

FIG. 3 is a front view similar to that of FIG. 1 with the rainhat beingsectioned.

FIG. 4 is a side view similar to that of FIG. 2 with the rainhat beingsectioned.

FIG. 5 is a bottom view of the rainhat aligned with the direction ofairflow through the rainhat.

FIG. 6 is an enlargement of the intersection between a support extendingin a first direction and a support extending in a second directionencircled in FIG. 4.

FIG. 6A is an enlargement of the intersection between a supportextending in a first direction and a rafter extending in a seconddirection encircled in FIG. 4.

FIG. 7 is an enlarged view of the barbed end fastener of the presentinvention which is encircled in FIG. 1.

FIG. 8 is a sectional view taking along line 8—8 of FIG. 2 illustratingthe mechanical interlocking and adhesive attachment of the adhesive tothe flange of the rainhat.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-4, a cowling 8 (FIG. 4) of an automotive vehicle isshown in phantom. The cowling 8 is positioned forward the vehiclewindshield underneath the hood which covers the vehicle enginecompartment. At least a portion of the cowling 8 provides a generallyplanar surface 10. The generally flat surface 10 portion of the cowlingencircles a flared opening 12. The flared opening 12 receives air forthe vehicle heating, ventilation and air conditioning system.

The high temperature injection molded polymeric rainhat 7 of the presentinvention is made from a high temperature polymeric substancethermoplastic such as polyamide, poly (phenylene sulphide),poly(butylene terephthalate) or other temperature resistantthermoplastic materials. The material should pass a 205° C. temperaturetest without significant distortion or degradation of the polymericmaterial. This will enable the rainhat 7 to pass through the electrocoatcurving oven and still maintain its functional integrity. In addition,the rainhat 7 material must be capable of passing through a phosphateimmersion tank without being damaged. A particularly preferred materialcommonly known as Nylon sold under the trademark Zytel, and ismanufactured by Dupont located in Wilmington, Del. Other importantrainhat 7 material characteristics include impact strength, elasticmodulus, tensile strength, and elastic strain to failure. Specificrequirements for the above characteristics will depend on specificdesign and attachment methods. The rainhat 7 has a flange 20. The flange20 joins the rainhat to the planar surface 10 portion of the cowlingwhich encircles the flared opening.

To provide a semi-structural bond to adhesively and sealably join theflange 20 to the planar surface 10 portion of the cowling, the flange 20has connected therewith an adhesive 22 (FIG. 8). The adhesive 22 isformed from a thermosetting formulated adhesive with a synthetic polymerbase which may incorporate magnetizable particles but in general doesnot. The adhesive (1) may provide a strong magnetic field; (2) melts attemperatures encountered in automotive paint ovens (between about 100and 235° C.) in order to flow over and around the generally planarsurface 10 portion of the cowling to be sealed; (3) bonds well to metalof the cowling; and (4) partially expands to fill any opening betweenthe flange 20 and the generally planar surface 10 portion of the cowlingencircling the flared opening 12. In addition, the adhesive 22 shouldpass any specifications determined to be important to the automotivemanufacturer that may include, but are not limited to, corrosionresistance, adhesive strength, toxicity, expansion, etc. Mostpreferably, the adhesive 22 is a hot melt sealant that volumetricallyexpands to some extend during curing.

The adhesive 22 includes as one component a synthetic polymer resin or ablend of resins and preferably includes one or more elastomers. In oneembodiment, where magnetic particles are, the adhesive 22 contains apolyolefin resin, a combination of ethylene vinyl acetate copolymer(EVA) and an acrylic resin such as ethylene methyl acrylate.

A cross-linking or curing agent is also preferably included in theadhesive 22 to cross-link the polyolefin. The cross-linking agent shouldprovide a reasonable shelf life, but should also be fully activated atthe temperatures encountered in the curing environment of an automotivepaint oven. A tackifier component is also included in the adhesive 22 toprovide adhesion and to enhance peel strength.

The adhesive 22 further may include ferritic magnetic particles whichcan provide the magnetic field that retains the rain hat flange 20 inposition on the flat surface 10 portion of the cowling. In a morereferred embodiment, the adhesive 22 further includes a multifunctionalcross-linking monomer such as trimethylolpropane trimethacrylate ortrimethylolpropane triacrylate to increase the cross-linking density ofthe adhesive 22. Additionally the adhesive 22 has an expansion agentwhich produces expansion of the adhesive 22 when it is melted in theautomotive paint oven to provide a more uniform and reliable seal ofrain hat flange to the generally planar portion of the cowling.Furthermore, the adhesive 22 includes a blowing agent which isthermally-activated. The blowing agent should be fully activated atabout 100 to about 200° C.

The adhesive should have a melt index that allows it to flowsufficiently during the sealing operation. A more detailed explanationof the adhesive can be gained from a review of U.S. patent applicationSer. No. 08/590,009 Czaplicki et al., the specification of which isincorporated by reference herein. However, other suitable sealants canbe utilized such as those commercially available from L & L Products.Suitable formulated materials include L-4200, L-2100 and L-4141.

Referring additionally to FIG. 8, the adhesive 22 is adhesively joinedto a bottom surface 24 of the flange 20. The flange 20 has a pluralityof vertically transverse bores. The adhesive 22 is molded to the flange20 such that it flows through the bores 26 and forms a head 28 on theopposite flange top surface 30. The adhesive 22 is therefore alsomechanically joined to the flange as well as adhesively joined thereto.

Referring additionally to FIG. 7, integral with the flange 20 andextending downward therefrom are three elongated fastener members 36.The fastener members 36 have a head 38 with compliant barbs 40. Thecompliant barbs 40 of the fastener members are extended throughpredrilled holes (not shown) in the cowling generally planar surface 10portion and thereafter retain the rainhat 7 in position before theflange 20 is adhesively joined to the cowling planar surface 10 portion.A mound 41 is provided to supply additional adhesive in and adjacent ahole which has a straight depression (not shown) in the cowling planarsurface 10. The rainhat flange 20 has one central forward fastenermembers 36. On a rearward side of the flange 20 there are two spacedapart fastener members 36. The fastener members 36 are inclined slightlyforward to accommodate a draw angle 130 of the rainhat 7.

Integrally joined to the flange 20 and extending vertically upwardtherefrom is a water dam 50. The water dam has an interior surface 52which closely engages the flared opening of the cowling. Any gap betweenthe bottom portion of the rain dam interior surface 52 and the flaredopening 12 of the cowling is also sealed by the adhesive 22, after ithas been cured. The rain dam interior surface 52 also extends upwardbeyond a vertical end 18 of the flared opening. The water dam has anextreme upper knife edge 54 forming an opening 62. The interior surfaceof the water dam front end has a central interior stop 56 (FIGS. 4 and5). The interior stop has a downward facing abutting edge 58 to makecontact with the vertical end 18 of the flared opening 56. A rear wallof the water dam on its interior surface may have, as shown, two spacedapart interior stops to make contact with the vertical end 18 of theflared opening. The water dam interior surface 52 near an upper end istapered at 60 to form the knife edge 54 with an exterior surface 64 ofthe water dam. The knife edge 54 aids in the prevention of leaves, leavestems or other debris laying on top the knife edge 54 of the rain dam.The opening 62 of the rain dam defines a predefined air inlet which issufficient for the needs of the heating, ventilation and airconditioning system of the vehicle.

Positioned on top of the water dam is a foreign matter ingestionpreventer 70. The foreign matter ingestion preventer 70 has a pluralityof first curvilinear supports 72 extending in a first direction over thewater dam opening 62. Each first support 72 is curvilinear havingopposite ends joined with the water dam 50. Each first support 72 has amiddle portion 74 domed above the opening 62 of the water dam. In thefirst direction there are three spaced apart supports 72. In otherembodiments (not shown) the number of first supports may vary. (SeeFIGS. 3 and 5, note the middle first support has been removed from FIG.5 for clarity of illustration). Each of the first supports 72 have aninterior side 76 and an exterior side 78. The exterior side 78 of eachfirst support is tapered and has a generally rounded edge. The exteriorside 78 of the first support at an end of the first support is flushwith the exterior surface 64 of the upper edge of the rain dam. Theinterior of each first support optionally extends downwardly into theinterior surface 52 of the water dam as shown in FIGS. 3 and 5. Theinterior edge 80 of the first support does not extend far enoughdownward to contact the upper end 18 of the flared opening. The firstsupports are typically 2 millimeters thick with a height of 6millimeters.

Extending generally parallel to the first supports in the firstdirection are a plurality of first rafters 84. (Note: Some first rafters84 have been removed from FIGS. 3 and 4 for clarity of illustration). Asshown in FIG. 5, the rain hat 7 has twelve first rafters 84, howevermore first rafters 94 may be included as desired. Each first rafter 84has opposite ends joining with the water dam. Typically the firstrafters will also be curvilinear in shape with a middle portion 86 beingdomed above the opening 62 of the water dam. Each first rafter 84 has aninterior side 88. Each first rafter also has an exterior side 90. Theexterior side of each first rafter 90 is tapered in a manner similarlydescribed for the first supports. An interior side 88 of the firstrafter are flush with an interior surface 52 of the water dam.

Extending from side to side are two curvilinear second supports 100(FIGS. 3, 4 and 5). In other embodiments (not shown) the number ofsecond supports may vary. The second supports are generallyperpendicular with the first supports. Each second support 100 has amiddle portion 102 extending over the water dam opening 62 with oppositeends joined to the water dam 50. Each second support has an interiorside 106. Each second support has an exterior side 108. The exteriorside 106 of each second support is tapered and has a generally roundededge 110 (FIG. 6). The second support exterior side 106 is flush withthe exterior side 106 is also flush with the exterior side 78 of thefirst support 72 and of the first rafters exterior side 90. The secondsupport are 2 millimeters thick with a height of 6 millimeters.

The rainhat additionally has second rafter 120. (Note: Some of thesecond rafters have been removed from FIGS. 3 and 4 for clarity ofillustration). The second rafters 120 of the rainhat extend in a seconddirection generally parallel to the second supports 100. The secondrafters have opposite ends joining with the water dam 50. The secondrafters have a curvilinear shape with a middle portion 122 being domedabove the opening 62 of the water dam (FIG. 5). Each second rafter 120has an interior side. Each second rafter also has an exterior side 122.An exterior side 124 of the second rafter is flush with the exteriorsurface 64 of the water dam. The exterior side 124 of the second raftersis also flush with the first supports 72 and the first rafters at theirintersection. The second rafters exterior side 126 (FIG. 6a) is taperedand has a particularly round end shape. The interior side 122 of thesecond rafters is flush with the interior surface 52 of the water dam.

The intersection of the first supports 72 and rafters 84 with the secondsupports 100 are essentially as shown in FIGS. 6 and 6a, for theintersections of the second supports 100 and rafters 120 with the firstsupport 72.

The rainhat 7 can be molded in a single draw mold machine. As shown, themain body of the rainhat 7 flange water dam and foreign matter ingestionpreventer is molded in a single draw mold machine The first and secondsupports 72, 100 are perpendicular with one another when looked(projected) in a plane perpendicular to the direction of the draw of themold which is used in forming the rainhat. The draw of the rainhat isgenerally parallel with the direction 130 of air inflow travel as shownin FIGS. 2 and 3. Slides are typically used to form the fastener member36.

The surface area of the foreign matter ingestion preventer 70 minus thetransverse area of the first support 72, second support 100, firstrafters 84 and second rafters 120 is equal to or greater than the areaof the opening 62 along the rain dam upper edge. To further aid airflowand to minimize fluid friction, the first and second rafters 89, 120 andsupports 72, 100 have an exterior side edge which are tapered aspreviously mentioned. It has ben empirically found that the tapering ofthe first and second supports 72, 100 and first and second rafters 84,120 improves airflow approximately 10%. Still another factor whicheffects airflow is the tapering of the knife edge 54 of the rain dam.The tapering serves two functions. The first function is theminimization of air friction. The second function is as previouslymentioned, it prevents debris from being lodged upon the knife edge 54.Additionally, leaves or other debris which fall upon the rainhat 7 willhave a tendency to become unbalanced and fall off due to the three axiscurvilinear features of the foreign matter ingestion preventer 70. Thedome of the foreign matter ingestion preventer allows the supports andrafters to be thicker yet still provide an opening with the low flowresistance required. Thicker supports and rafters are desired due toincreased strength, durability, and moldability.

In operation, the rainhat 7 is typically manually positioned over theflared opening 12 of the cowling. The rainhat 7 is pushed downwardallowing the fastener members 36 to enter into the predrilled openingsof the cowling 8. The barbs 40 of the fastener members 36 are contractedby the holes in the cowling planar surface 10 portion. Once past theholes the fastener member barbs 36 again extend to then capture therainhat 7 to the cowling. The vehicle is then taken into an electrolytebath. The rising of temperature caused by the paint ovens after theelectrolytic bath causes the adhesive 22 to expand and to adhesively andsealably connect the rainhat 7 to the vehicle cowling. The barbedfasteners retain the rainhat 7 in position until the curing andexpanding process of the adhesive 22 is complete.

While the present invention was illustrated and described with respectto a preferred embodiment, such description is exemplary only and notlimiting in nature. Other aspects, objects, and advantages of thisinvention may be obtained from the study of the drawings, and thedisclosure. It is well understood by those skilled in the art thatvarious changes and modifications can be made in the invention withoutdeparting from the spirit and scope thereof, which is limited only bythe appended claims.

What is claimed is:
 1. A high temperature injection molded polymericrainhat for a heating, ventilation, and air-conditioning air intake ofan automotive vehicle, the vehicle having a cowling with a generallyplanar surface, the planar surface encircling a flared opening in thecowling, the rainhat comprising: a flange for adhesively and sealablyjoining to a portion of the generally planar surface encircling theflared opening; a water dam integrally joined to the flange andextending therefrom, the water dam having an interior surface closelyengaging the flared opening of the cowling and extending upwards beyonda vertical end of the flared opening, and the water dam having anextreme upper edge forming an opening; and a foreign matter ingestionpreventer, the foreign matter ingestion preventer having at least onefirst curvilinear support extending in a first direction over the waterdam upper edge opening, each first support having opposite ends joinedwith the water dam, and each first support having a middle portion beingdomed above the opening of the water dam upper edge, each first supporthaving the interior side and an exterior side with the exterior sidebeing tapered, the foreign matter ingestion preventer having at leastone second curvilinear support intersecting with the first curvilinearsupport, the second curvilinear support extending in a second directionover the flared opening, and each second support having opposite endsjoined with the water dam, and each second support having a middleportion being doomed above the opening of the water dam, each secondsupport having an interior side and an exterior side with the exteriorside being tapered, wherein a surface area of the foreign matteringestion preventer minus the surface area defined by the transversedimensions of the supports is generally equal to or greater than thearea defined by the opening of the upper edge of the water dam.
 2. Ahigh temperature injection molded polymeric rainhat as described inclaim 1 with a plurality of first supports.
 3. A high temperaturesinjection molded polymeric rainhat as described in claim 2 with aplurality of second supports.
 4. A high temperature injection moldedpolymeric rainhat as described in claim 1, wherein there is an axis oftravel of airflow through the rainhat and the first and second supportsform a rectangular image on a plane which is perpendicular to the axisof travel of airflow through the rainhat.
 5. A high temperatureinjection molded polymeric rainhat as describe in claim 1, furtherincluding first rafters generally parallel to the first support, thefirst rafters extending in a first direction over the opening of thewater dam edge, each first rafter having opposite ends joining with thewater dam, with a middle portion being domed above the opening of thewater dam upper edge and each first rafter having an interior side andan exterior side, with the exterior side being tapered, the firstrafters intersecting with the second curvilinear supports wherein thearea of the foreign matter ingestion preventer minus the surface definedby the transverse dimensions of the area of the first and secondsupports and first rafters is equal or greater to the area defined bythe opening of the upper edge of the water dam.
 6. A high temperatureinjection molded polymeric rainhat as described in claim 1, furtherincluding second rafters generally parallel to the second support, thesecond rafters extending in a second direction over the flared openingof the water dam upper edge, each second rafter having opposite endsjoining with the water dam, with a middle portion being domed above theopening of the water dam upper edge and each second rafter having aninterior side and an exterior side, with the exterior side beingtapered, the second rafters intersecting with the first curvilinearsupports and wherein the area of the foreign matter ingestion preventerminus the surface defined by the transverse dimension of the area of thefirst and second supports and second rafters is equal to or greater tothe area defined by the opening of the upper edge of the water dam.
 7. Ahigh temperature injection molded polymeric rainhat as described inclaim 1, wherein the supports exterior surface is flush with theexterior surface of the upper edge of the rain dam.
 8. A hightemperature injection molded polymeric rainhat as described in claim 1,wherein an interior of the water dam has interior stops to make contactwith an upper edge of the flared opening.
 9. A high temperatureinjection molded polymeric rainhat as described in claim 1, wherein theflange has descending therefrom a plurality of elongated fastenermembers with compliant barbed heads for insertion into prepared holes inthe cowling to connect the rainhat with the cowling before the rainhatis adhesively joined to the cowling.
 10. A high temperature injectionmolded polymeric rainhat as described in claim 1, wherein the first andsecond rafters have an exterior which is flush with the exterior surfaceof the water dam.
 11. A high temperature injection molded polymericrainhat as described in claim 1, wherein the first and second raftershave an interior which is flush with an interior surface of the waterdam.
 12. A high temperature injection molded polymeric rainhat asdescribed in claim 1, wherein an interior surface of the water dam istapered to an interior surface of the water dam to form an upper edge.13. A high temperature injection molded polymeric rainhat as describedin claim 1, wherein a heat expanding sealant is adhesively andmechanically joined to the flange.
 14. A high temperature injectionmolded polymeric rainhat as described in claim 1, wherein the rainhat ismolded from Nylon.
 15. A high temperature injection molded polymericrainhat as described in claim 1, wherein the rainhat flange, water damand foreign matter injection preventer are made in a single drawinjection mold machine.
 16. A high temperature injection moldedpolymeric rainhat for a heating, ventilation, and air-conditioning airintake of an automotive vehicle, the vehicle having a cowling with agenerally planar surface, the planar surface encircling a flared openingin the cowling, the rainhat comprising: a flange for adhesively andsealably joining to a portion of the cowling generally planar surfaceencircling the flared opening, the flange has descending therefrom aplurality of elongated fastener members with compliant barbed heads forinsertion into prepared holes in the cowling to connect the rainhat withthe cowling; a heat expanding sealant adhesively and mechanically joinedto the flange; a water dam integrally joined to the flange and extendingtherefrom, the water dam having an interior surface closely engaging theflared opening of the cowling and extending upwards beyond a verticalend of the flared opening, and the water dam having an extreme upperknife edge forming an opening and an interior surface of the water damis tapered to an exterior surface of the water dam to form the upperknife edge, and an interior surface of the water dam has interior stopsto make contact with an upper edge of the cowling flared opening; and aforeign matter ingestion preventer, the foreign matter ingestionpreventer having a plurality of first curvilinear supports extending ina first direction over the water dam upper edge opening, each firstsupport having opposite ends joined with the water dam, and each firstsupport having a middle portion being domed above the opening of thewater dam upper edge, each first support having the interior side and anexterior side with the exterior side being tapered, and the firstsupports exterior side being flush with the exterior surface of thewater dam the foreign matter ingestion preventer having a plurality ofsecond curvilinear supports intersecting with the first curvilinearsupports, the second curvilinear supports extending in a seconddirection over the water dam, and each second support having oppositeends joined with the water dam, and each second support having a middleportion being domed above the opening of the water dam, each secondsupport having an interior side and an exterior side with the exteriorside being tapered and the second supports exterior side being flushwith the exterior surface of the water dam, the foreign matter ingestionpreventer further including first rafters generally parallel to thefirst supports, the first rafters extending in a first direction overthe opening of the water dam, each first rafter having opposite endsjoining with the water dam, each first rafter having a middle portionbeing domed above the opening of the water dam, each first rafter havingopposite ends joining with the water dam, each first rafter having amiddle portion being domed above the opening of the water dam and eachfirst rafter having an interior side and an exterior side with theexterior side of the first rafter being tapered and the first rafter hasends flush with the exterior surface of the water dam, and the firstrafter interior side being flush with an interior surface of the waterdam, and the foreign matter ingestion preventer further including secondrafters generally parallel to the second supports, the second raftersextending in a second direction over the opening of the water dam, eachsecond rafter having opposite ends joining with the water dam, eachsecond rafter having a middle portion being domed above the opening ofthe water dam and each second rafter having an interior side and anexterior side and the ends of the second rafter being flush with theinterior and exterior surfaces respectively of the water dam, and thesecond rafter exterior side being tapered, the second raftersintersecting with the first curvilinear supports and rafters, andwherein the area of the foreign matter ingestion preventer minus thesurface defined by the transverse dimensions of the area of the firstand second supports and first and second rafters is equal or greater tothe area defined by the opening of the water dam.
 17. A high temperatureinjection molded polymeric rainhat as described in claim 14, whereinthere is an axis of travel of airflow through the rainhat and the firstand second supports project a rectangular image on a plane which isperpendicular to the axis of travel of airflow through the rainhat. 18.A high temperature injection molded polymeric rainhat as described inclaim 1 wherein the rainhat flange, water dam and foreign matterinjection preventer are made in a single draw injection mold machine.19. A single integral rainhat comprising: a flange for adhesively andsealably joining to a portion of an automotive vehicle having a cowling;a water dam integrally joined to the flange and extending therefrom, thedam further having an interior surface for closely engaging anautomotive vehicle cowling, and an extreme upper edge forming anopening; a foreign matter ingestion preventer joined with the water damhaving a plurality of first curvilinear supports extending in a firstdirection over the water dam upper edge opening and a plurality ofsecond curvilinear supports intersecting with the first curvilinearsupports.
 20. A rainhat as described in claim 19, wherein a surface areaof the foreign matter ingestion preventer minus a surface area definedby the transverse dimensions of the first and the second supports isgenerally equal to or greater than an area defined by the opening of theupper edge of the water dam.
 21. A rainhat as described in claim 20,wherein each first curvilinear support of the foreign matter ingestionpreventer comprises: opposite ends joined with the water dam, a middleportion domed above the opening of the water dam, and a tapered exteriorside.
 22. A rainhat as described in claim 20, wherein each secondsupport of the foreign matter ingestion preventer comprises: oppositeends joined with the water dam, a middle portion domed above the openingof the water dam, and a tapered exterior side.
 23. A rainhat asdescribed in claim 20, wherein there is an axis of travel of airflowthrough the rainhat and the first and second supports project arectangular image on a plane which is perpendicular to the axis oftravel of airflow through the rainhat.
 24. A rainhat as described inclaim 24 wherein the flange adhesively and sealably joins to a portionof an automotive vehicle cowling having a generally planar surfaceencircling a flared opening, the cowling flared opening having avertical end.
 25. A rainhat as described in claim 24 wherein the waterdam interior surface closely engages the flared opening of the cowlingand extends upwards beyond the cowling vertical end.
 26. A rainhat asdescribed in claim 19 wherein the rainhat is formed from a hightemperature injection molded polymeric material.
 27. A rainhat asdescribed in claim 27 wherein the rainhat flange, water dam and foreignmatter injection preventer are made in a single draw injection moldmachine.
 28. A rainhat as described in claim 19, wherein a heatexpanding sealant is adhesively and mechanically joined to the flange.29. A rainhat as described in claim 26, wherein the rainhat is moldedfrom Nylon.
 30. A single integral rainhat for a heating, ventilation,and air-conditioning air intake of an automotive vehicle, the vehiclehaving a cowling, the rainhat comprising: a flange for adhesively andsealably joining to a portion of cowling; a water dam integrally joinedto the flange and extending therefrom, the water dam having an interiorsurface closely engaging the cowling and the water dam having an extremeupper edge forming an opening; and a foreign matter ingestion preventer,the foreign matter ingestion preventer having a plurality of firstcurvilinear supports extending in a first direction over the water damupper edge opening and a plurality of second supports intersecting withthe first curvilinear supports.
 31. A rainhat as described in claim 30,wherein a surface area of the foreign matter ingestion preventer minus asurface area defined by the transverse dimensions of the first and thesecond supports is generally equal to or greater than an area defined bythe opening of the upper edge of the water dam.
 32. A rainhat asdescribed in claim 31, wherein each first curvilinear support of theforeign matter ingestion preventer comprises: opposite ends joined withthe water dam, a middle portion domed above the opening of the waterdam, and a tapered exterior side.
 33. A rainhat as described in claim31, wherein each second support of the foreign matter ingestionpreventer comprises: opposite ends joined with the water dam, a middleportion domed above the opening of the water dam, and a tapered exteriorside.
 34. A rainhat as described in claim 31, wherein there is an axisof travel of airflow through the rainhat and the first and secondsupports project a rectangular image on a plane which is perpendicularto the axis of travel of airflow through the rainhat.
 35. A rainhat asdescribed in claim 30 wherein the cowling has a generally planar surfaceencircling a flared opening, the cowling flared opening having avertical end.
 36. A rainhat as described in claim 35 wherein the flangeadhesively and sealably joins to a portion of the cowling generallyplanar surface encircling the flared opening.
 37. A rainhat as describedin claim 35 wherein the water dam interior surface closely engages theflared opening of the cowling and extends upwards beyond the cowlingvertical end.
 38. A rainhat as described in claim 31 wherein the rainhatis formed from a high temperature injection molded polymeric material.39. A single integral rainhat for a heating, ventilation, andair-conditioning air intake of an automotive vehicle, the vehicle havinga cowling, the rainhat comprising: a flange for adhesively and sealablyjoining to a portion of cowling; a heat expanding sealant adhesively andmechanically joined to the flange; a water dam integrally joined to theflange and extending therefrom, the water dam having an interior surfaceclosely engaging the cowling and the water dam having an extreme upperedge forming an opening; and a foreign matter ingestion preventer fordiscouraging the entrapment of leaves or other articles which can clogup air intake openings, the foreign matter ingestion preventer having aplurality of first curvilinear supports extending in a first directionover the water dam upper edge opening and a plurality of secondcurvilinear supports intersecting with the first curvilinear supports.40. A rainhat as described in claim 39, wherein a surface area of theforeign matter ingestion preventer minus a surface area defined by thetransverse dimensions of the first and the second supports is generallyequal to or greater than an area defined by the opening of the upperedge of the water dam.
 41. A rainhat as described in claim 40, whereineach first curvilinear support of the foreign matter ingestion preventercomprises: opposite ends joined with the water dam, a middle portiondomed above the opening of the water dam, and a tapered exterior side.42. A rainhat as described in claim 40, wherein each second support ofthe foreign matter ingestion preventer comprises: opposite ends joinedwith the water dam, a middle portion domed above the opening of thewater dam, and a tapered exterior side.
 43. A rainhat as described inclaim 40, wherein there is an axis of travel of airflow through therainhat and the first and second supports project a rectangular image ona plane which is perpendicular to the axis of travel of airflow throughthe rainhat.
 44. A rainhat as described in claim 39 wherein the cowlinghas a generally planar surface encircling a flared opening, the cowlingflared opening having a vertical end and wherein the water dam interiorsurface closely engages the flared opening of the cowling and extendsupwards beyond the cowling vertical end.
 45. A rainhat as described inclaim 39 wherein the rainhat is formed from a high temperature injectionmolded polymeric material.
 46. A rainhat as described in claim 45wherein the rainhat flange, water dam and foreign matter injectionpreventer are made in a single draw injection mold machine.